Load cell for screw piling power head

ABSTRACT

A system to measure the installation torque of a screw pile comprises machinery suitable to drive the screw pile into the ground, said machinery further comprising a rotary drive suspended by means of a universal joint-type coupler. A load pin, having at least one sensor, is mounted through the universal joint-type coupler as a pivot pin and is oriented within the universal joint-type coupler so that at least some of the installation torque is transmitted through said load pin and is measurable by said at least one sensor. Preferably, the load pin further comprises a pair of bores and a plurality of sensors are provided and mounted within the bores. More preferably, a differential bridge network is used to obtain a measurable signal from the plurality of sensors.

CROSS REFERENCE TO RELATED APPLICATION

This application is a regular application of U.S. Provisional PatentApplication Ser. No. 61/749,310 filed Jan. 5, 2013 and entitled, “LOADCELL FOR SCREW PILING POWER HEAD”, the entirety of which is incorporatedherein by reference.

FIELD OF THE INVENTION

The present invention relates generally to equipment and techniques formeasuring torque applied to objects and, more particularly, to a loadcell to measure torque applied to a screw piling by a rotary drive.

BACKGROUND OF THE INVENTION

The background information discussed below is presented to betterillustrate the novelty and usefulness of the present invention. Thisbackground information is not admitted prior art.

Screw piling or screwpiles are a steel screw-in piling and groundanchoring system used for building foundations, pipeline tie-downs andin other applications. Screw pile(s), as used herein, includes screwpiling, steel screw-in foundations, screw piers, helical piles, helicalanchors, screw anchors, screw foundations and helical piers. They areoften necessary for building foundations where the ground is notcompacted, or strong enough or of variable capacity to carry a buildingstructure. Screwpiles are typically manufactured using varying sizes oftubular hollow sections for the pile or anchor shaft. The pile shafttransfers a structure's load into the pile. Helical steel plates, orhelixes, are welded to the pile shaft in accordance with the intendedground conditions.

To install screw piling, they are typically wound into the ground muchlike a screw into wood. Screw piles are preferably installed usingearthmoving equipment or mobile machinery fitted with drive attachmentswhich may include rotary drives, rotary drivers, powerheads or driveheads, see, for example, FIGS. 1 a and 1 b. The mobile machinery variesfrom skid-steer loaders to 5 ton through 30 ton excavators. Rotarydrives, generally with torque capacities ranging from 5,000 Nm to300,000 Nm, are custom fitted using various boom configurations. Driveattachments generally connect the screwpile to the machine. Likewise,hinged attachment means, such as a universal joint-type coupler, areoften employed to suspend the rotary drive attachment from the boom ofthe mobile machinery; see, for example, FIG. 1 b. One or more pivot pinsmay be utilized to connect the coupler to the boom and the driveattachment see, for example, the coupler disclosed in U.S. Pat. No.6,942,430.

The level of torque that is required to turn the screw pile isindicative of the strength of the soil, and can be used to predict thecapacity of the pile. Low installation torque indicates a weak soil andlow pile capacity, whereas high installation torque indicates arelatively strong soil and greater pile capacity. Where the requiredinstallation torque can be accurately measured, the approximate holdingcapacity of a screw pile can be reliably predicted.

Traditionally, estimates of installation torque were made usinghydraulic pressure gauges (to measure the amount of hydraulic pressureprovided to a rotary drive), assumed or estimated gearbox ratios andcompensation for any hydraulic motor losses. However, such estimates arefairly inaccurate and may not reliably predict a screw pile's holdingcapacity. As such, various devices and systems have been created to moreaccurately measure the installation torque of a screw pile.

One example is that by Pro-Dig, LLC of Kansas, U.S.A., which markets ascrew pile torque monitoring system under the trade-mark INTELLI-TORK™.This system comprises a flanged member that mounts between the rotarydrive and the screw piling and, therefore, rotates along with the screwpiling as it is driven into the ground. As the rotary drive impartstorque to the screw piling, sensors in the flanged member measure thistorque. Because this flanged member rotates along with screw piling itmust send its measurements wirelessly to a display or recorder. As such,one disadvantage of this system is that such wireless signals may besubject to interference from the vibrations created during screw pilinginstallation, especially as the screw piling is almost installed and theflanged member is driven closer to the ground.

A further disadvantage of this system is that the flanged member addsadditional length to the rotary drive/screw pile assembly, therebyshortening the maximum length of screw pile that can potentially beinstalled using a particular mobile machinery. Yet a furtherdisadvantage is that the INTELLI-TORK™ system also appears to be subjectto interference from downward forces that may be applied by the mobilemachinery as it pushes the rotary drive/screw pile assembly downwardsduring installation.

Another example is that by Russell Neale Engineering Pty Ltd of BurleighHeads, Queensland, Australia, which markets a screw pile torquemonitoring system under the trade-mark TORQATRON™. This system comprisesa load cell member that mounts between the boom of the mobile machineryand the rotary drive. Unlike the flanged member of the INTELLI-TORK™system, this load cell member does not rotate with the screw piling asit is driven into the ground (since it is mounted between above therotary drive and to the boom). As such, wired connections can be used totransmit signals from the load/torque sensors in the TORQATRON™.However, this device and system does suffer from the other disadvantagespresent in the INTELLI-TORK™ system, namely that the load cell memberadds additional length to the boom/rotary drive/screw pile assembly,thereby shortening the maximum length of screw pile that can potentiallybe installed using a particular mobile machinery that it also appears tobe subject to interference from downward forces that may be applied bythe mobile machinery as it pushes the boom/rotary drive/screw pileassembly downwards during installation.

Therefore, what is needed is a system and apparatus to measure theinstallation torque of a screw pile which is simple in design and doesnot have the above-mentioned disadvantages.

SUMMARY OF THE INVENTION

The present invention is directed to overcoming the prior artdeficiencies in load cells used to measure torque applied to a screwpiling by a rotary drive, such being subject to interference fromdownward forces and such as adding additional length to the boom, rotarydrive and screw pile assembly during operations.

In one aspect the invention provides a system to measure theinstallation torque of a screw pile which comprises machinery suitableto drive the screw pile into the ground, said machinery furthercomprising a rotary drive suspended by means of a universal joint-typecoupler. A load pin, having at least one sensor, is mounted through theuniversal joint-type coupler as a pivot pin and is oriented within theuniversal joint-type coupler so that at least some of the installationtorque is transmitted through said load pin and is measurable by said atleast one sensor.

Preferably, the load pin further comprises a pair of bores and a set offour foil gauge strain gauge sensors are mounted within each of the pairof bores in a mirror-like fashion, with one bore being the mirror imageof the other. More preferably, a differential bridge network is used toobtain a measurable signal from the plurality of sensors.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring to the drawings, several aspects of the present invention areillustrated by way of example, and not by way of limitation, in detailin the figures, wherein:

FIG. 1 a is a side view of a PRIOR ART system for installing screwpilings;

FIG. 1 b is a perspective view of another PRIOR ART system forinstalling screw pilings wherein the rotary drive is suspended from aboom by a universal joint coupler;

FIG. 2 a is a perspective view of one embodiment of the load cellaccording to the present invention, shown mounted in a universal jointcoupler suspended between a boom and a rotary drive;

FIG. 2 b is an enlarged view of the embodiment of FIG. 2 a, taken ofarea 6 in FIG. 2 a;

FIG. 3 a is a sectioned perspective view of the load cell of theembodiment of FIG. 2 a, shown mounted in a universal joint and takenalong line 2-2 in FIG. 2 b;

FIG. 3 b is a sectioned perspective view of the load cell of theembodiment of FIG. 2 a, shown mounted in a universal joint and takenalong line 1-1 in FIG. 2 b;

FIG. 3 c is an enlarged view of the embodiment of FIG. 2 a, taken ofarea 8 in FIG. 3 b and schematically illustrating a cantilever effectfor each of the four strain gauge sensors in area 8;

FIG. 4 is another sectioned perspective view of the load cell of theembodiment of FIG. 2 a, shown mounted in a universal joint and takenalong line 2-2 in FIG. 2 b;

FIGS. 5 a and 5 b are perspective views of the load cell of theembodiment of FIG. 2 a, with access cover being removed in FIG. 5 b;

FIG. 6 a is a sectioned perspective view of the load cell of theembodiment of FIG. 2 a, taken along line 5-5 in FIG. 5 b;

FIG. 6 b is a sectioned perspective view of the load cell of theembodiment of FIG. 2 a, taken along line 3-3 in FIG. 5 a;

FIG. 7 a is a sectioned perspective view of the load cell of theembodiment of FIG. 2 a, taken along line 4-4 in FIG. 5 a;

FIG. 7 b is an enlarged view of the embodiment of FIG. 2 a, taken ofarea 6 in FIG. 6 b;

FIG. 8 is another sectioned perspective view of the load cell of theembodiment of FIG. 2 a;

FIG. 9 a is a another perspective view of the load cell of theembodiment of FIG. 2 a;

FIG. 9 b a sectioned perspective view of the load cell of the embodimentof FIG. 2 a, taken along line 8-8 in FIG. 9 a;

FIG. 10 a is another sectioned perspective view of the load cell of theembodiment of FIG. 2 a, taken along line 7-7 in FIG. 5 a, wherein end ofthe load cell is being subjected to a 5000 lb downward force while it isinstalled in a coupler of a preferred system embodiment;

FIG. 10 b is an electrical schematics of how a Wheatstone bridge networkelectrically connects a preferred embodiment of four strain gauges andillustrating one example of an output signal (voltage) generated by thestresses on the load cell of FIG. 10 a as it experienced the 5000 lbdownward force;

FIG. 10 c is an electrical schematics of a differential bridge networkemployed by the invention to electrically connect a preferred embodimentof four strain gauges and illustrating one example of an output signal(voltage) generated by the stresses on the load cell of FIG. 10 a as itexperienced the 5000 lb downward force;

FIG. 11 a is another sectioned perspective view of the load cell of theembodiment of FIG. 2 a, taken along line 7-7 in FIG. 5 a, wherein theload cell is being subjected to an installation torque force of 5000 lbwhile it is installed in a coupler of a preferred system embodiment;

FIG. 11 b is an electrical schematics of how a Wheatstone bridge networkelectrically connects a preferred embodiment of four strain gauges andillustrating one example of an output signal (voltage) generated by thestresses on the load cell of FIG. 11 a as it experienced the 5000 lbinstallation torque force;

FIG. 11 c is an electrical schematics of a differential bridge networkemployed by the invention to electrically connect a preferred embodimentof four strain gauges and illustrating one example of an output signal(voltage) generated by the stresses on the load cell of FIG. 11 a as itexperienced the 5000 lb installation torque force;

FIG. 12 a is a perspective view of the load cell of the embodiment ofFIG. 2 a, showing a preferred layout of eight foil strain gauge sensorsarranged within a pair of through-bores;

FIG. 12 b is an electrical schematics of a preferred pair of Wheatstonebridge networks electrically connecting the eight strain gauges of theload cell of FIG. 12 a; and

FIG. 12 c is an electrical schematics of a preferred pair ofdifferential bridge networks electrically connecting the eight straingauges of the load cell of FIG. 12 a.

DEFINITION SECTION

Horizontal plane, as used herein, refers to a plane that is horizontalat a given point if it is perpendicular to the gradient of the gravityfield at that point, in other words, apparent gravity is what makes aplumb bob hang perpendicular to the plane at that point. In other wordsa horizontal plane in the plane that is perpendicular to the line thatpasses through the center of the Earth.

Vertical plane, as used herein, refers in astronomy, geography,geometry, and related sciences and contexts, to a direction passing by agiven point if it is locally aligned with the gradient of the Earth'sgravity field, i.e., with the direction of the gravitational force (perunit mass, i.e. gravitational acceleration vector) at that point.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description is of a preferred embodiment by way of exampleonly and without limitation to the combination of features necessary forcarrying the invention into effect. Reference is to be had to theFigures in which identical reference numbers identify similarcomponents. The drawing figures are not necessarily to scale and certainfeatures are shown in schematic or diagrammatic form in the interest ofclarity and conciseness.

In accordance with a preferred embodiment of the present invention andas shown generally in Figures, there is a provided a system 10 tomeasure the installation torque T of a screw pile 12 which generallycomprises at least one load cell 14 having at least one sensor 16 fordetecting the load, force or strain on the cell 14. Preferably, loadcell 14 is in the form of a pin and is placed or positioned, within themachinery used to drive the screw pile 12 into the ground so that all,or substantially all, of the installation torque T is transmittedthrough said at least one sensor 16 so as to measure that installationtorque. Load cell 14 will also be referred to as load pin 14 whendiscussing a preferred embodiment of the invention. The machinery usedto drive the screw pile 12 into the ground may be a skidsteer loader,excavator or some other suitable machinery.

In a preferred embodiment, the machinery used to drive the screw pile 12into the ground comprises a suitable rotary drive 18 suspended from aboom 20 by means of a universal joint 22 (see FIG. 2 a). The rotarydrive 18 can be of the type disclosed in U.S. Pat. No. 6,942,430, thedisclosures of which are hereby incorporated by reference, or of someother conventional rotary drive.

In a preferred embodiment, the rotary drive 18 is shown suspended fromthe boom 20 by a universal joint-type coupler 22 having an upper section22 u and a lower section 221. Preferably, coupler's upper section 22 uis pivotally connected to the boom 20 between two ears 20 i, 20 ii(having through bores) via pivot pin member 24 in a conventional manner.More preferably, the rotary drive 18 is pivotally suspended from thecoupler's lower section 221, via ears 18 i, 18 ii whereby load pin 14 ismounted through an axial passage 22 a in the coupler's lower section 221and through bores 18 a and 18 b provided in each of said ears 18 i, 18ii.

Preferably, and as is conventional in a universal joint-type coupler,pins 14 and 24 have their pivot axis oriented at 90° relative to eachother. Wear sleeves, wear members, bushings or bearings 19 a, 19 b maybe provided between load pin 14 and through bores 18 a, 18 b tofacilitate pivotal movement of the rotary drive 18 with the coupler 22.Likewise, wear sleeves, wear members, bushings or bearings may beprovided between pivot pin 24 and through-bores in ears 20 i, 20 ii.

In accordance with normal practice, the tolerances between the parts areselected to prevent binding, to allow the desired pivotal movement andto permit easy assembly and disassembly. As such, load pin 14 functionsas a pivot pin to pivotally connect the rotary drive 18 to coupler'slower section 221. Preferably lower section 221 has its pivot axisoriented at 90° to the pivot axis of the upper section 22 u with theboom 20, as is customary in a universal joint. More preferably, load pin14 is mounted through the coupler's lower section 221 so that themajority of the axial body 14 a is covered or enveloped by the coupler'slower section 221 and/or the bushings 19 a, 19 b, with only the ends 14e, 14 f extending out of the coupler's lower section 221 and the throughbores 18 a, 18 b (see FIG. 3 a, for example).

In this embodiment, all or substantially all of the installation torqueT is transmitted from the rotary drive 18 (as applied to the screw pile12 during installation) through the coupler 22 and to boom 20. By virtueof the load pin 14 being used as one of the pivot pins in the universaljoint-type coupler 22, some or all of the installation torque T is alsotransmitted through said pin 14 and detectable or measurable by said atleast one sensor 16.

In an alternate embodiment (not shown), load pin may be mounted in theconnection between the upper section 22 u and the boom 20 in place ofpivot pin 24 and a conventional pivot pin may then be used to pivotallyconnect the rotary drive 18 to the lower section 22. In yet a furtheralternate embodiments (also not shown), the rotary drive 18 is suspendedfrom the boom 20 by only a single pivoting joint (e.g. such as thatshown in FIG. 1 a) and then load pin 14 will be used as the pivot pin atsuch single pivoting connection.

Preferred Embodiment of the Load Cell

In a preferred embodiment, and referring now to FIG. 6 a, load pin 14 isan elongate cylindrical member having an axial body 14 a withlongitudinal axis A extending between opposing ends 14 e, 14 f,preferably formed as one part and in one solid piece. Axial body 14 ahas a medial portion 14 m, having a center point CM along longitudinalaxis A, and two peripheral portions 14 p, 14 p′. Medial portion 14 m isadapted to mount through the axial passage 22 a of the coupler's lowersection 221. The peripheral portions 14 p, 14 p′ are adapted to mountthrough bores 18 a, 18 b and any wear members 19 a, 19 b that may beprovided.

Between the medial portion 14 m and the two peripheral portions 14 p, 14p′, the axial body 14 a has transitional portions 15 a, 15 b of aslightly smaller outside diameter than the medial 14 m and peripheralportions 14 p, 14 p′ so as to allow some movement and/or bending of theload pin 14 at these portions 15 a, 15 b when installed in a coupler 22and when subjected to installation torque T.

Preferably, the transitional portions 15 a, 15 b function as forcemeasuring zones 26 a, 26 b, each having at least one sensor 16 arrangedor mounted somewhere therein. More preferably, transitional portions 15a, 15 b are between 1 cm and 5 cm in width (i.e. width/spacing betweenmedial and peripheral portions), which allows for sufficient movementand/or bending of the load pin (to allow the at least one sensor 16function properly) while not weakening the load pin unnecessarily andstill allow it to safely function as a pivot pin within a coupler 22.Even more preferably, transitional portions 15 a, 15 b are positionedalong the load pin's longitudinal axis A so that they are substantiallycentered along the interface I of the coupler's lower section 221 andthe respective wear members 19 a, 19 b, so that a maximum amount ofshear force (between the load pin portion within the coupler's lowersection 221 and the load pin portion that is within the through bores 18a, 18 b and any wear members 19 a, 19 b) can be directed into saidtransitional portions 15 a, 15 b and said force measuring zones 26 a, 26b (see FIG. 3 c). However, the system 10 will work effectively as longas said interface I is positioned at any point along the transitionalportions 15 a, 15 b. Yet even more preferably, the transitional portions15 a, 15 b are the same distance from the center point CM and aresubstantially mirror images of each other.

More preferably, the system 10 comprises a plurality of sensors 16mounted on the interior of one or more bores or holes 28 a, 28 b, insaid one or more of the transitional portions 15 a, 15 b and said forcemeasuring zones 26 a, 26 b. In the preferred embodiment, bores 28 a and28 b are equidistant from the center point CM of the medial portion 14 mand are mirror images of each other.

Preferably, load pin 14 is provided with an internal passage 30 thatconnects bores 28 a, 28 b to each other and, more preferably, extends toat least one end (e.g. end 14 e) of the load pin 14. Axial passage 30 ispreferably coaxial with the longitudinal axis A, but it need not be.Advantageously, electrical conductors (not shown) can be run throughaxial passage 30, e.g. between the bores 28 a, 28 b and out toward oneof the ends 14 e of the load pin 14, so as to facilitate electricalconnection of, and signal transfer from, the at least one sensor 16 toan external display, signal amplifier or recorder (not shown) and/orelectrical connection of a plurality of sensors 16 to each other and/orto an external display, signal amplifier or recorder.

More preferably, axial passage 30 near the end 14 e may be enlarged atsaid end 14 e, so as to accommodate additional electrical circuitry,such as a printed circuit board assembly 32, to assist with sensorsignal processing, amplification and/or transmission of the sensorsignals to the external display or recorder. Even more preferably,printed circuit board assembly 32 is provided with a conventional levelsensor or accelerometer (not shown), to provide sensory data regardingthe amount of tilt or displacement (if any) of the load pin'slongitudinal axis A relative to the horizontal plane H. Yet even morepreferably, axial passage 30 near end 14 e exits at said end 14 e, suchas along the longitudinal axis A at position 14 i, or at a perpendicularangle to the longitudinal axis, such as at position 14 j, or at both.Still even more preferably, a wiring connector or socket 34 is providedto facilitate a removable electrical signal connection between the atleast one sensor 16 and any external display, signal amplifier orrecorder and to sealable close passage 30; and a cap 36 is provided tosealable close passage 30 at 14 i once printed circuit board assembly 32is installed within enlarged end of passage 30.

Preferred Embodiment of the Bores

Bores 28 a, 28 b may be blind ended, but preferably bores 28 a, 28 b arethrough-bores (i.e. going fully through the load pin 14) with eachhaving a bore axis B, B′ arranged in a radial fashion and beingsubstantially perpendicular to the longitudinal axis A of the load pin14. Advantageously, through-bores 28 a, 28 b provide for easy ofassembly and mounting of the sensors 16 within the load pin 14 (e.g. bybeing able to manipulate and access the sensors 16 from either of twosides of the load pin 14 at either openings to bores 28 a, 28 b or bybeing able to pull sensor wiring therethrough from one side to theother). More advantageously, sensors 16 are protected (from weather,contamination and physical damage) by virtue of being mounted on theinterior of load pin 14 in the bores 28 a, 28 b and, then, by virtue ofthe load pin being installed within (and substantially covered by) axialpassage 22 a of the coupler's lower section 221.

Preferably, one or more substantially flattened or planar regions 28 a′,28 a″, 28 b′, 28 b″ are provide on the interior surface of bores 28 a,28 b, with said planar regions being of sufficient surface area to mountthe at least one sensor 16 (e.g. as shown in FIG. 8). More preferably,each of bore 28 a, 28 b is provided with two planar regions in a pairedarrangement (e.g. 28 a′, 28 a″ for bore 28 a, and 28 b′, 28 b″ for bore28 b), wherein said two planar regions in each bore are substantiallyparallel to, but on either side of, a central plane CP of the load pin14 (which runs along the longitudinal axis A). Yet even more preferably,the two planar regions in each bore are equidistant from the centralplane CP (see, for example, FIGS. 8 and 9 b).

Advantageously, the planar regions 28 a′, 28 a″, 28 b′, 28 b″ make foran easier mounting surface, for the at least one sensor 16, as comparedto the curved surface of a conventional through-bore. Preferably, theplanar regions 28 a′, 28 a″, 28 b′, 28 b″ have a width ranging between0.75 inches to 2 inches, so as to accommodate a pair of sensors 16mounted side-by-side on each of said planar regions (see, paired R1, R2and paired R5, R6 on planar regions 28 a′ and 28 b′ in FIG. 6 a, forexample). In the preferred embodiment, the planar regions 28 a′, 28 a″,28 b′, 28 b″ have a width of approximately 1 inch. Moreover, a jig (notshown) comprised of a simple flatten bar or metal strip, of just under 1inch wide, and having cut outs for the sensors 16, can be utilized toposition paired sensors inside a bore (e.g. 28 a) in a consistent mannerand placement across multiple load pins 14 that may be manufactured;e.g. by sliding such jig along a planar section (e.g. along 28 a′) to apredetermined point and then gluing or mounting the paired sensors 16.

Preferred Embodiment of the at Least One Sensor

Preferably, the at least one sensor 16 is a transducer such as a foilstrain gauge, glued or otherwise mounted to the inner surface of the oneor more bores or holes 28 a, 28 b. Foil strain gauges are well known inthe art as sensors to transduce deformation (due to application offorce) into electrical resistance change. In particular, as the interiorof the bores 28 a, 28 b (and the planar regions 28 a′, 28 a″, 28 b′, 28b″) are deformed, any foil gauges mounted thereon are also deformed,causing the strain gauge's electrical resistance to change. Conventionalelectronic network circuitry and measurement calculations can then beutilized to translate output from the at least one sensor 16 intocorresponding force measurements, such as torque T.

Referring to FIG. 7 b, typical strain gauges 16, R1,R2 are shownarranged as a long, thin conductive strip in a zig-zag pattern ofparallel lines such that a small amount of stress in the direction ofthe orientation of the parallel lines PL results in a multiplicativelylarger strain over the effective length of the conductor and, moreover,results in the strain gauge being far more sensitive to strain andforces in the orientation of the parallel lines PL than in the directionthat is substantially perpendicular to the orientation of parallel linesPL (said substantially perpendicular direction indicated by arrowlabelled PD and being mostly insensitive to strain).

In a preferred embodiment, the load pin 14 comprises eight foil straingauge sensors 16, identified as R1, R2, R3, R4, R4, R6, R7 and R8, withR1 to R4 being mounted within bore 28 a and R5 to R8 mounted within bore28 b. Preferably, all the strain gauge sensors 16, R1-R8 are mountedwithin their respective bores 28 a, 28 b of the load pin 14 so that theorientation of their parallel lines PL are substantially parallel to theload pin's longitudinal axis A the central plane CP of the load pin 14,and substantially perpendicular to their respective bore axis B or B′(see FIGS. 7 b, 8).

More preferably, each set of four foil strain gauge sensors 16 isarranged within their respective bore 28 a, 28 b so that two of thegauges in each bore are in a first (same) plane on one side of the loadpin's central plane CP and substantially parallel to the longitudinalaxis A (e.g. see FIG. 7 b), while the other two gauges are in a secondplane on the other side of the load pin's central plane CP and are alsosubstantially parallel to the longitudinal axis A; see FIG. 8 where R1and R2 are on one side of the longitudinal axis A in a plane thatcorresponds substantially with planar region 28 a′, while R3 and R4 areon the other side of the longitudinal axis in a plane that correspondssubstantially with planar region 28 a″. A corresponding arrangementapplies for R5 to R8, as also shown in the figures. Preferably, theplane of one set of paired sensor gauges 16 (e.g. planar region 28 a′having R1 and R2) is equidistance from the central plane CP as comparedto the plane of the other set of paired sensor gauges (e.g. planarregion 28 a″ having R3 and R4). More preferably, the spacing SP betweeneach sensor 16 in a set of paired sensor gauges 16 (e.g. between R1 andR2) is the same and consistent as compared to the spacing SP between thesensors 16 in all the other paired sensor gauges 16 in the system 10(e.g. between R3 and R4). Yet even more preferably, the arrangement ofsensors 16 in the other bore (e.g. R5-R8 in bore 28 b) is a mirror imageof the arrangement of the sensors 16, R1-R4 in the first bore 28 a.Preferably, a flat bar type of jig, as noted above, may be utilized toobtain such consistent spacing SP between paired sensors within a singleload pin 14 and across multiple load pins during manufacturing.

In a preferred embodiment, such spacing SP between sensors in a set ofpaired sensor gauges is in the range of 0.5 to 0.625 inches,center-to-center of adjacent sensors (see FIG. 7 b for example).However, a closer spacing SP of paired sensor gauges 16, such as ¼ inchcenter-to-center, will also work but may result in slightly lowersensory output when the sensors are arranged in a network bridge circuit(as further explained below). Likewise, a further or wider spacing SP ofpaired sensor gauges 16, such as 1.5 inch center-to-center spacing, willagain work and may even provide greater signal output when using theelectronic bridge circuitry as described below. However, such further(wider) spacing will require wider bores 28 a, 28 b which may weaken theload pin 14 so that it become unsuitable as a pivot pin to pivotallyconnect the rotary drive 18 to coupler's lower section 221 and/or ismore sensitive to unexpected and inconsistent stress and shear errorswhich may be picked up and/or amplified by such wider-spaced sensors 16.

Preferred orientation of load pin installation within couplerPreferably, when the load pin 14 is placed within a coupler 22, whereinits longitudinal axis A will be oriented substantially parallel to thehorizontal plane H (see FIGS. 2 a, 4), and wherein the load pin 14 isrotated or mounted so that bores 28 a, 28 b (and their bore axis B, B′and their planar regions 28 a′, 28 a″, 28 b′, 28 b″) are orientedsubstantially parallel to the vertical plane V and, hence, alsosubstantially parallel to the axis of rotation of the screw pile 12,which is generally driven into the ground in vertical manner (see FIGS.2 a, 4). Advantageous, when foil strain gauges are utilized as thesensor 16 the parallel lines PL thereof are then substantially parallelto horizontal H and, therefore, the much less sensitive orientation ofthe foil strain gauge sensor 16 (direction PD) is substantially parallelto vertical V. Advantageously, any torque T imparted to the screw pile12 by the rotary drive 18 will be applied in a perpendicular manner tosaid bore axis B, B′ and planar regions 28 a′, 28 a″, 28 b′, 28 b″ (see,for example, FIGS. 9 b and 9 c) and can be picked-up, or sensed, by theat least one sensor 16 via the much more sensitive parallel lines PL.More advantageously, any downward force DF is directed through thesensors 16 along the much less sensitive direction PD and therefore willnot be picked up by overall sensing system and/or the system 10 willoverall be less affected by such downward force DF. Preferably, theorientation of the bore axis B, B′ does not deviate more than 7 to 10degrees (plus or minus) from being parallel to the vertical plane V.

In contrast, and as will now be appreciated by those skilled-in-the art,if the orientation of the bore axis B, B′ is further deviated and issubstantially parallel to the horizontal plane H, then: (a) any torque Timparted to the screw pile 12 by the rotary drive 18 will be applied ina parallel manner to said bore axis B, B′ and will be sensed by the atleast one sensor 16 via the much less sensitive direction PD and (b) anydownward force DF is directed through the sensors 16 along the much moresensitive parallel lines PL. Such an orientation of the load pin 14within the coupler 22 would, therefore, not be desirable and wouldlikely create unknown and unexpected errors; or require significantcalibration of the load pin 14 to compensate for such errors and/orunknowns.

Preferably, the load pin 14, once mounted within the coupler 22 is thedesired orientation, is locked in place using a conventional end-cap(not shown) that may be attached to end 14 f. Alternatively, the loadpin 14 may be locked in place (in the desired orientation) via welding,keyed members, cross-pins, locking pins or other conventional means.

Connection of Sensors within Each Bore

Although not preferred, the sets of strain gauges in each bore (e.g.R1-R4 in bore 28 a and R5-R8 in bore 28 b) may each be electricallyinterconnected using a conventional Wheatstone bridge electronic circuitor network 40; see, for example, FIGS. 10 b and 11 b illustrating howone set of strain gauges R1-R4 in bore 28 a may be interconnected in aWheatstone bridge fashion (strain gauges R5-R8 in bore 28 b thenlikewise being interconnected using a second similar Wheatstone bridgenetwork). In particular, in this Wheatstone bridge fashion, one branchor leg of the bridge circuit 40 is comprised of two foil strain gauges16 (which act as the resistors within the bridge circuit) that aremounted on opposing planar regions within a particular bore (e.g. R1 onplanar region 28 a′ and R3 on opposing planar region 28 a″ form the leftbranch of the circuit; see FIGS. 10 a and 10 b). The other branch or legof the bridge circuit 40 is likewise comprised of the two remaining foilstrain gauges 16 that are also on opposing planar regions, relative toeach other (e.g. R2 on planar region 28 a′ and R4 on opposing planarregion 28 a″ form the right branch of the circuit; see FIGS. 10 a and 10b).

The Wheatstone bridge network 40 is energized by a suitable source ofelectric potential 42 and may have additional electronics such astemperature control resistors 46 and calibration resistors 48 as isconventional with such bridge circuits. Using conventional foil straingauges, when no force is applied to the load pin 14, the sensors 16,R1-R8 remain at their normal resistance values (e.g. at 3500 (ohms)),the bridge circuit is balanced and the signal voltage (Vsig) istherefore at zero. However, when a force is applied (e.g. a 5000 lbdownward force DF as in FIGS. 10 a-10 c; or a 5000 lb torque force as inFIGS. 11 a-11 c) any unbalance in flow of electric current through thestrain gauges R1-R4 of the network circuit 40 creates a measurablesignal 44 that may be measured, recorded or amplified by an externaldisplay, signal amplifier or recorder (not shown) in a conventionalmanner to determine and calculate the amount of force or torque Tapplied.

Although a Wheatstone bridge network 40 will be responsive to, and canbe used to measure, installation torque T and provide a measurablesignal 44 relating thereto, there are some disadvantages to using aWheatstone bridge network 40. In particular, the inventor has observedthat such a Wheatstone bridge network 40 (as used with the preferredembodiment a set of four foil strain gauges within one of the two bores)is still somewhat sensitive to downward forces DF, even if the downwardforce DF is directed through the sensors 16 along the much lesssensitive direction PD.

Therefore, in a preferred embodiment a set of four foil strain gaugeswithin a bore (e.g. R1-R4 in bore 28 a) is electrically interconnectedusing a differential bridge electronic circuit or network 50. Inparticular, in this differential bridge fashion, one branch or leg ofthe bridge circuit 50 is comprised of two foil strain gauges 16 (whichact as the resistors within the bridge circuit) that are mounted on thesame planar region within a particular bore (e.g. R3 and R4, both onplanar region 28 a″ form the left branch of the circuit; see FIGS. 10 aand 10 c). The other branch or leg of the differential bridge circuit 50is comprised of the two remaining foil strain gauges 16 that are on theopposing planar region as compared to the first two foil gauges whichmake up the first branch of the circuit (e.g. R1 and R2 on planar region28 a′ form the right branch of the circuit; see FIGS. 10 a and 10 c).

The differential bridge network 50 is energized by a suitable source ofelectric potential 52 and may have additional electronics such astemperature control resistors 56 and calibration resistors 58 as isconventional with such bridge circuits. When no force is applied to theload pin 14, the sensors 16, R1-R8 remain at their normal resistancevalues (e.g. at 3500 (ohms)), the bridge circuit is balanced and thesignal voltage 54 (Vsig) is therefore at zero. However, when a force isapplied any unbalance in flow of electric current through the straingauges R1-R4 of the network 50 creates a measurable signal 54 that maybe measured, recorded or amplified by an external display, signalamplifier or recorder (not shown) in a conventional manner to determineand calculate the amount of force or torque T applied.

Advantageously, the inventor has observed that a differential bridgenetwork 50 (as used with the preferred embodiment of a load pin 14having at least one set of four foil strain gauges within a bore andsaid pin 14 being oriented within coupler as described above in thepreferred orientation) is much less sensitive to any downward forces DFthan using a Wheatstone bridge network 40.

Preferably, during manufacturing or afterwards, the particularelectronic bridge network 40 or 50 of a particular load pin 14 iscalibrated using a test bed or similar calibration machine, and usingconventional calibration techniques.

EXAMPLE

Now referring to FIGS. 12 a-12 c, the eight foil strain gauges in eachbore (e.g. R1-R4 in bore 28 a and R5-R8 in bore 28 b) of the preferredembodiment are may be electrically interconnected to provide a singlemeasureable signal 44, 54 using either a pair of connected Wheatstonebridge electronic networks 40,40′ (see FIG. 12 b) or a pair of connecteddifferential bridge electronic networks 50,50′ (see FIG. 12 c).

Using the preferred embodiment of the load pin 14 and oriented in thepreferred orientation within the coupler 22, as described herein, andwherein the sensors 16, R1-R8 are conventional foil strain gauges havingnormal (i.e. no force being applied) resistance values of 3500 (ohms),each pair of sensors mounted on a planar region (as shown in theFigures) and having a center-to-center spacing of 0.625 inches and whereexcitation voltage (Vinput, +EX/−EX) is 10 Volts (although the signalvoltage change (Vsig) being reported as millivolts-per-volt (mV/V)), andutilizing either a pair of connected Wheatstone bridge electronicnetworks 40,40′ (of the embodiment of FIG. 12 b) or a pair of connecteddifferential bridge networks 50,50′ (of the embodiment of FIG. 12 c),the inventor observed the following signal values (in millivolts/volt)with respect to a 5000 lb force applied to the pin 14, either asdownward force DF or as torque T (as noted), as shown in the tablebelow:

Downward Force Torque Force Wheatstone bridge network −0.02381 mV/V0.22631 mV/V (40,40′ in FIG. 12b) Differential bridge network (50, 0.00106 mV/V 0.19863 mV/V 50′ in FIG. 12c)

As can be seen, both types of networks (Wheatstone bridge vsdifferential bridge) provide a similar magnitude of signal in a responseto a 5000 lb torque force (i.e. 0.22631 mV/V and 0.19863 mV/V).Therefore, both types of networks 40 or 50 are suitable to detect andmeasure torque forces T that may be applied to a screw pile 12.Advantageously, however, the differential bridge network provides asignificantly lower signal when the load pin 14 is subjected to adownward force than does a Wheatstone bridge network (0.00106 mV/V fordifferential vs−0.02381 mV/V for Wheatstone). In fact, the observeddifference was more than an order of magnitude smaller when using thedifferential bridge network. Advantageously then, utilizing a load pin14 of the preferred embodiment as described herein, along with the eightfoil strain gauges electrically connected using a paired differentialbridge network 50, 50′, results in a system 10 capable of providing asignal representative of the installation torque T of a screw pile 12while being unaffected (or only very minimally affected) by any downwardforces DF.

More advantageously, the inventor has observed that such preferredembodiment, i.e. wherein the through-bores 28 a, 28 b are equidistantfrom the center point CM of the medial portion 14 m, wherein each ofbores 28 a, 28 b is provided with two planar regions in a pairedarrangement, wherein the planar regions in each bore are equidistantfrom the central plane CP, wherein the arrangement of sensors 16 in oneof the bores (e.g. R5-R8 in bore 28 b) is a mirror image of thearrangement of the sensors 16, in the other bore (e.g. R1-R4 in bore 28a) and wherein the sensors 16, R1-R8 are connected to generate a signal54 using a pair of differential bridge networks 50,50′, the load pin 14and the system 10 are insensitive (or only minimally sensitive) to bothdownward forces DF and to point loading of the pin, such as if the pin14 is mounted somewhat off-center within the coupler's lower section221. Thus the preferred embodiment of the pin 14 and system 10 allowsfor a non-point source measurement of installation torque T that is notaffected by downward forces DF. Moreover, now a conventional hingedmember, such as a universal joint or simple pivot connector can beadapted or retro-fit to measure installation torque T and no additionaldevices are necessary which would otherwise lengthen the screwpileinstallation machinery (as is the case with the above-notedINTELLI-TORK™ and TORQATRON™ systems).

Those of ordinary skill in the art will appreciate that variousmodifications to the invention as described herein will be possiblewithout falling outside the scope of the invention. For example,although the load pin 14 herein is shown as a single elongatecylindrical member having an axial body 14 a with longitudinal axis Aextending between opposing ends 14 e, 14 f, preferably formed as onepart and in one solid piece, it is also contemplated that the inventionwill work with a two-part (or split) load pin (not shown), wherein eachof the two parts of such pin would correspond to the peripheral portions14 p, 14 p′ (with corresponding ends 14 e and 14 f) along with theappropriate transitional portions 15 a, 15 b, and wherein with themedial portion 14 m is then split into two parts (and each such partsthen corresponding with the relevant transitional portions 15 a or 15b). In such an embodiment, each of the two parts of the split load pinis then mounted within the coupler 22 in the preferred orientation andwherein each part is mounted substantially the same distance from whatwould otherwise be the center of the medial portion CM of a single loadpin 14.

In the claims, the word “comprising” is used in its inclusive sense anddoes not exclude other elements being present. The indefinite article“a” before a claim feature does not exclude more than one of thefeatures being present.

The embodiments of the invention in which an exclusive property orprivilege is being claimed are defined as follows:
 1. A system tomeasure the installation torque of a screw pile, the system comprising:machinery suitable to drive the screw pile into the ground, saidmachinery further comprising a rotary drive suspended by means of auniversal joint-type coupler; and a load pin having at least one sensor,said load pin mounted through the universal joint-type coupler as apivot pin; wherein the load pin is oriented within the universaljoint-type coupler so that at least some of the installation torque istransmitted through said load pin and is measurable by said at least onesensor.
 2. The system of claim 1 wherein the at least one sensor is afoil strain gauge.
 3. The system of claim 1 wherein the load pin is anelongate cylindrical member having an axial body with a longitudinalaxis extending between opposing ends.
 4. The system of claim 3 whereinthe axial body comprises a medial portion having a center point alongsaid longitudinal axis, and two peripheral portions at each of saidopposing ends.
 5. The system of claim 4 wherein the axial body furthercomprises a pair of transitional portions, each of said transitionalportion being located between each of the two peripheral portions andthe medial portion, said transitional portions being of slightly smallerdiameter than said medial and peripheral portions, the transitionalportions being substantially mirror images of each other.
 6. The systemof claim 5 wherein said at least one sensor is mounted within one ofsaid transitional portion.
 7. The system of claim 6 wherein the load pinfurther comprises at least one bore within each of said transitionalportions
 8. The system of claim 7 wherein there are two bores, each ofwhich located within each of said pair of transitional portions and eachbeing a through-bore having a bore axis oriented substantiallyperpendicular to the longitudinal axis of the load pin, wherein saidpaired transitional portions and their respective through-bores areequidistant from said center point.
 9. The system of claim 8 whereinsaid two bores each further comprise two planar regions on theirrespective interior surfaces, said planar regions within each bore beingsubstantially parallel to, and located equidistant on either side of, acentral plane of the load pin, thereby forming a total of four planarregions.
 10. The system of claim 8 wherein there are at least twosensors, each of said sensors being mounted to the interior of saidbore.
 11. The system of claim 9 wherein there are eight sensors, saideight sensors being mounted pairwise to each of the four planar regions.12. The system of claim 11 wherein the sensors are foil strain gaugeshaving parallel lines, the sensors being more sensitive to strain andforces that are in the orientation of said parallel lines.
 13. Thesystem of claim 12 wherein said foil strain gauges are mounted withintheir respective bores of the load pin so that the orientation of theirparallel lines are substantially parallel to the load pin's longitudinalaxis.
 14. The system of claim 13 wherein each set of four foil straingauge sensors is arranged within their respective bore so that two ofthe foil strain gauges in each bore are one side of the load pin'slongitudinal axis, while the other two gauges in such bore are on theother side of the load pin's longitudinal axis.
 15. The system of claim14 wherein two of each of the set of four foil gauges are equidistancefrom the central plane of the load pin as compared to the other two ofthe set of four foil gauges.
 16. The system of claim 8 wherein, thescrew pile has an axis of rotation and wherein, when the load pin ismounted through the universal joint-type coupler, said bores areoriented substantially parallel to said axis of rotation of the screwpile.
 17. The system of claim 15 wherein, the screw pile has an axis ofrotation and wherein, when the load pin is mounted through the universaljoint-type coupler, said bores are oriented substantially parallel tosaid axis of rotation of the screw pile.
 18. The system of claim 15wherein each of the set of four foil gauges within a bore areelectrically connected using a Wheatstone bridge electronic circuit. 19.The system of claim 15 wherein each of the set of four foil gaugeswithin a bore are electrically connected using a differential bridgeelectronic circuit.
 20. The system of claim 15 wherein each of the setof four foil gauges within a bore are electrically connected using abridge circuit and wherein one branch said bridge circuit is comprisedof two foil strain gauges that are mounted on the same planar regionwithin said bore and the other branch of the bridge circuit is comprisedof the two remaining foil strain gauges that are on the opposing planarregion.
 21. The system of claim 19 wherein the eight foil strain gaugesin each bore are electrically interconnected to provide a singlemeasureable signal using a pair of connected differential bridgeelectronic circuits.
 22. A load pin for mounting through a universaljoint-type coupler and for measuring the installation torque of a screwpile, the load pin comprising: at least one sensor; wherein the load pinis suitable to also function as a pivot pin when mounted through saiduniversal joint-type coupler; and wherein the load pin is capable ofbeing oriented within the universal joint-type coupler so that at leastsome of the installation torque is transmitted through said load pin andis measurable by said at least one sensor.
 23. The load pin of claim 22wherein the at least one sensor is a foil strain gauge.
 24. The load pinof claim 22 wherein the load pin is an elongate cylindrical memberhaving an axial body with a longitudinal axis extending between opposingends and wherein the axial body further comprises a medial portionhaving a center point along said longitudinal axis, two peripheralportions at each of said opposing ends and a pair of transitionalportions, each of said transitional portion being located between eachof the two peripheral portions and the medial portion, said transitionalportions being of slightly smaller diameter than said medial andperipheral portions, the transitional portions being substantiallymirror images of each other.
 25. The load pin of claim 24 wherein saidat least one sensor is mounted within one of said transitional portion.26. The load pin of claim 25 wherein the load pin further comprises atleast one bore within each of said transitional portions.
 27. The loadpin of claim 26 wherein there are two bores, each of which locatedwithin each of said pair of transitional portions and each being athrough-bore having a bore axis oriented substantially perpendicular tothe longitudinal axis of the load pin, wherein said paired transitionalportions and their respective through-bores are equidistant from saidcenter point.
 28. The load pin of claim 27 wherein said two bores eachfurther comprise two planar regions on their respective interiorsurfaces, said planar regions within each bore being substantiallyparallel to, and located equidistant on either side of, a central planeof the load pin, thereby forming a total of four planar regions.
 29. Theload pin of claim 28 wherein there are eight sensors, said eight sensorsbeing mounted pairwise to each of the four planar regions.
 30. The loadpin of claim 29 wherein the sensors are foil strain gauges havingparallel lines, the sensors being more sensitive to strain and forcesthat are in the orientation of said parallel lines.
 31. The load pin ofclaim 29 wherein said foil strain gauges are mounted within theirrespective bores of the load pin so that the orientation of theirparallel lines are substantially parallel to the load pin's longitudinalaxis.
 32. The load pin of claim 31 wherein two of each of the set offour foil gauges are equidistance from the central plane of the load pinas compared to the other two of the set of four foil gauges.
 33. Theload pin of claim 32 wherein each of the set of four foil gauges withina bore are electrically connected using a Wheatstone bridge electroniccircuit.
 34. The load pin of claim 32 wherein each of the set of fourfoil gauges within a bore are electrically connected using adifferential bridge electronic circuit.
 35. The load pin of claim 32wherein each of the set of four foil gauges within a bore areelectrically connected using a bridge circuit and wherein one branchsaid bridge circuit is comprised of two foil strain gauges that aremounted on the same planar region within said bore and the other branchof the bridge circuit is comprised of the two remaining foil straingauges that are on the opposing planar region.
 36. The load pin of claim35 wherein the eight foil strain gauges in each bore are electricallyinterconnected to provide a single measureable signal using a pair ofconnected differential bridge electronic circuits.